Compact hybrid cell hydrogen generator

ABSTRACT

A compact hybrid cell hydrogen generator that produces hydrogen-oxygen gas for use with vehicles, internal combustion engines and other applications that solves design shortcomings of present state of the art systems while presenting an efficient and reliable, compact, cost efficient system of producing hydrogen-oxygen gas without requirements or investments into expensive infrastructure, or ill fitting and cumbersome equipment.

BACKGROUND-CROSS REFERENCE Parent Case Text

This utility patent application is based upon, and claims the priority filing date, of my previously-filed, co pending U.S. Provisional Patent Application entitled “Compact Hydrogen Generator”, Ser. No. 61/252,612 filed Oct. 16, 2009

U.S. Patent Documents

3,256,504 June 1966 Fidelman 3,652,431 March 1972 Reynolds 3,761,382 September 1973 Hammond, et al. 3,933,614 July 1975 Bunn 4,077,863 March 1978 Nasser 4,081,656 March 1978 Brown 4,513,065 April 1985 Adlhart 4,737,161 April 1988 Szydlowski, et al. 4,726,888 February 1988 McCambridge 5,082,544 January 1992 Wiley, et al. 5,231,954 August 1993 Stowe 5,277,994 January 1994 Sprouse 5,711,865 January 1998 Caesar 5,888,361 March 1999 Hirai 6,209,493 April 2001 Ross 6,379,525 April 2002 Clements 6,857,397 February 2005 Zagaja 7,191,737 March 2007 Klein 7,273,044 September 2007 Flessner, et al. 7,459,071 December 2008 Omasa 7,524,342 April 2009 Brinkley 7,811,529 October 2010 Powell, et al

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to compact hydrogen generators, more particularly, the invention relates to hydrogen generators so constructed as to disassociate both oxygen and hydrogen simultaneously within the same electrolytic chamber, the resulting combined hydrogen-oxygen gas necessitating neither pressurizing or storage but drawn off and used immediately to assist in powering hydrocarbon based motors and engines to assist in lowering emissions and boosting fuel efficiency. While there are other renditions of various hydrogen generators, they are quite bulky and are impractical for use in the mobile environment of a vehicle, therefore presently claimed invention is particularly useful and novel in providing a compact on-demand hydrogen system.

2. Description of the Prior Art

The addition of a mixture of hydrogen gas (H.sub.2) and oxygen gas (O.sub.2) to the fuel system of an internal combustion engine is known to improve fuel efficiency and decrease the emission of undesired pollutants. These benefits are thought to be the result of more complete combustion induced by the presence of hydrogen such that fuel efficiency increases and incomplete combustion products—soot and carbon monoxide—decrease. The hydrolysis of water is known to produce both hydrogen gas and oxygen gas. Water is of course non-flammable and extremely safe. However, hydrogen is a flammable gas that is potentially explosive. Accordingly, utilization of hydrogen in vehicular applications must be undertaken with caution.

Most state of the art systems designed for on-demand hydrogen generation as used presently in vehicles, are based on either the “wet cell” or the “dry cell” electrolyzer designs. While there are many different iterations existing within these two categories, the overall designs are based on one of the above two categories.

Wet Cell

The wet cell consists of a metallic plate stack immersed in a bath of electrolytic solution. This is the most common method of electrolysis and is most widely used in industry today. The dry cell design by contrast is relatively new state of the art. It is a plate stack usually comprised of flat plates, clamped together with gaskets separating each plate, and holes being present between them to allow the flow of water and electrolyte in between.

Because wet cell designs are immersed in electrolytic solution, they have good laminar flow which is good for hydrogen production. However, their exposed plate edges allow the current to jump from sharp edge to sharp edge, creating electrical and magnetic eddies. Those resultant edge currents cause losses of power and efficiency because much of the energy leaps around the water/electrolyte mixture instead of transferring through it between the plates (where the majority of electrolysis takes place). This works in industrial settings with access to the grid power and high voltages and current, but does not work well in mobile applications where efficiency and portability are key factors for success.

Dry Cell

The dry cell designs eliminate edge currents by utilizing gaskets that encircle the plates completely, effectively keeping the exposed edges “outside” of the electrolytic bath. The electrolytic solution flows through small holes in between each plate. While these designs eliminate edge current inefficiencies, the reduced laminar flow is quite restricted causing foaming of electrolytic solution, which can then enter engines and destroy sensitive aluminum parts internally. It also causes poor heat transfer due to restrictive fluid dynamics and gas back-pressures, thereby lowering efficiencies of the system.

Additionally, most dry cell units have the exposed plate edges on the outside of the unit, making them quite dangerous and subject to arcing and shorts if anything metallic falls or drops on them during operation. Huge currents of 30 to 40 amps are flowing in between the plates. The smallest loose screw or even road salt from winter snow removal can cause a short or create an arc (similar to a welder) on the outside of the plates creating dangerous conditions for a hydrogen generator in a mobile setting around other combustible fuels such as gas or diesel, rendering it quite dangerous for use in mobile operations.

While the wet cell and dry cell designs have both advantages and disadvantages by way of efficiencies and gas production, neither is perfected in its present form, and both are in need of revision.

Various techniques have been attempted in the prior art to develop electrolyzers and hydrogen generators which will supply hydrogen gas as a fuel additive to existing motors and engines of various sizes U.S. Pat. No. 6,209,493 B1 (the '493 patent) and U.S. Pat. No. 5,231,954 (the '954 patent) disclose an electrolysis cell that is used to provide hydrogen and oxygen to the fuel system of an internal combustion engine. The '493 patent discloses a kit that uses such an electrolysis cell to produce hydrogen and oxygen that may either be separated or mixed before the gases are introduced to a vehicle fuel system. Although each of these systems may increase fuel efficiency, each system is complicated by one or more undesirable features. For example, the prior art systems do not have internal components shielded against losses due to current flowing across the exposed edges of plates. Furthermore, these electrolysis systems tend to have electrodes that do not have a very high surface area. Hydrogen and oxygen can be produced more efficiently with electrodes having greater surface area. Furthermore, these systems are very bulky and not easily able to be fit into vehicles without expensive and time consuming modifications, especially vehicles of newer design where under hood space is at best, minimum.

Some state of the art hydrogen generators operate with high pressure gas storage, which requires heavy and bulky cylinders as in U.S. Pat. No. 4,077,863 (the '863 patent). These types can pose an explosion hazard in the event of rupture due to severe impact, and some versions require an expensive infrastructure in place for refilling. Other hydrogen generators utilize consumptive cathodic or anodic materials as in U.S. Pat. No. 4,513,065 (the '065 patent) and U.S. Pat. No. 7,524,342 (the '342 patent), which are used up in the electrolytic process and must be routinely replaced and disposed of, creating a cumbersome disadvantage in refueling as well as the extra environmental burdens imposed by the hazardous waste.

Bulky and Cumbersome

Still other hydrogen generators use highly complicated methods of gas separation and require bulky generators and other apparatus with various membranes to separate, compress, and store the hydrogen from the oxygen into multiple tanks for later use or introduce it into a fuel cell for further processing as in U.S. Pat. No. 7,811,529 (the '529 patent) which also renders the cost of the generator so expensive as to be impractical for the average consumer. Still other generators use various means of vibrating or moving the plates to create a better fluid flow like U.S. Pat. No. 7,459,071 (the '071 patent), but again the huge size required renders it useless for vehicle applications where a compact generator is a necessity.

Further examples of wet cell power being wasted as the electrical energy jumps from exposed sharp edges of metal plates and screens can be found in U.S. Pat. No. 7,191,737 (the '737 patent) and U.S. Pat. No. 5,711,865 (the '865 patent). While these generators are sufficient for their design and general use in a static setting, they are neither practical nor possible to use in vehicles or the mobile market which have little room for such massive additional mechanisms of storage and control, and their inefficiencies waste energy that could be better focused on the production of the clean fuel additives of hydrogen and oxygen.

Additionally, recent state of the art hydrogen generators designed for vehicles and mobile industries operate at a steady state, and therefore require auxiliary and complex systems to maintain this state. Temperature control and amperage control are two factors which affect those systems.

Most current state of the art on-demand hydrogen generators are constructed of a plastic material with low forming temperatures. If amperages are left uncontrolled, the heat generated will melt the container or warp the existing container materials. This can cause electrolyte leakage and dangerous loss of hydrogen from the system, and ultimately failure of the unit and many of the existing state of the art controllers are not built to withstand the constant heavy current needed to produce substantial hydrogen-oxygen gas. They often fail or burn out, rendering the entire hydrogen generation unit useless.

Therefore, these specific applications of hydrogen generators of prior art as used to enhance the combustion process of internal combustion engines, are often bulky, impractical, and unsatisfactory. Accordingly, there exists a need of an improved compact hydrogen-generating system.

3. OBJECTS AND ADVANTAGES

Accordingly, several objects and advantages of my invention are a result of the unique hybrid cell combination of both wet cell and dry cell technologies, drawing on the strengths of both, while eliminating the weaknesses inherent in each, resulting in a more balanced system of efficiency, fluid dynamics, and hydrogen-oxygen production, while at the same time meeting the important practical criteria for being a compact hydrogen generator.

While present state of the art hydrogen generation systems are bulky, heavy, expensive, and complex, and in some cases in need of an infrastructure to utilize, my compact hybrid cell hydrogen generator by contrast, is light weight and very compact, and is engineered to fit into most existing vehicles with little modification. Because they are of the class of “on-demand” hydrogen-oxygen generators, they require no infrastructure or dangerous storage tanks, eliminating the need for billions of dollars in pumping stations. All hydrogen is used immediately upon production, and is only made as needed, requiring no storage, no compressors, and no tanks, making it much safer to use and eliminating the dangers of explosions from crashes.

Rated at the same gas production rate as current state of the art systems, the compact hybrid cell hydrogen generator of this invention is from 10%-50% of the size of current state of the art systems, making it among the most compact and practical for use in mobile systems today.

While present systems require expensive and complicated electronic controllers to prevent thermal runaway and resulting meltdowns, my present invention utilizes a unique design which does not require any electronic control, is thermally stable, and can withstand amperage levels two to three times as high as current state of the art units, without experiencing melting or overheating. It is also constructed of high temperature plastics rated at over 300 degrees F. These type of plastics, while expensive, can withstand even the hottest engine bay temperatures without melting or thermoforming, thereby creating a more efficient, more robust unit designed to take the rigors of mobile vehicle use.

My compact hybrid cell hydrogen generator operates in a continuous varying state, i.e. the temperature and current are permitted to rise to their final value using an external reservoir, a measured electrolyte/water ratio, and superb internal fluid dynamics. By eliminating the expensive and troublesome electronic controllers, my present invention reduces costs, ensures reliability, and reduces installation time and maintenance.

The wet cells have the advantage of great laminar flow in creating vast amounts of hydrogen-oxygen gas, but their severe losses due to exposed edges negate many of the advantages. My unique compact hybrid cell hydrogen generator takes advantage of the improved laminar flow of wet cells, while sealing off most exposed edges, greatly reducing the losses that would normally occur, but maintaining comparable flow.

The dry cell eliminate edge currents, but their problems with dangerous exposed and electrified edges can create a hazardous situation and possible explosions. My compact hybrid cell hydrogen generator completely encloses the plate edges reducing or eliminating any danger of sparks from shorting between the plates. My present invention also maintains the efficiencies of a dry cell by greatly reducing edge current losses in its unique internal design.

Additionally, the foaming that occurs often in certain dry cell designs can cause loss of power, decreased hydrogen production, and if it reaches the engine, the caustics in the foam can eat away at aluminum parts found in many engines today, possibly causing expensive repair bills to the owner. Therefore it is imperative to keep foaming to a minimum. My unique compact hybrid cell hydrogen generator mimics the efficiencies of the dry cell, but additionally maintains the effective laminar flow rate of a wet cell to greatly reduce foaming and restricted gas flow, resulting in a more efficient system.

While current state of the art designs utilizing wet cell or dry cell technology have both advantages and disadvantages by way of efficiencies, cost, and hydrogen-oxygen gas production, neither is perfect in its present form, and both are in need of revision.

There are other objects and advantages that will become apparent from the specification and drawings.

SUMMARY

Now in accordance with this invention there has been found a compact hybrid cell hydrogen generator apparatus with unique design and structure for use in vehicles and static applications where a decrease of emissions and a better extraction of energy from hydrocarbonic fuels is desired and needed. In this embodiment my present invention of a compact hybrid cell hydrogen generator solves design shortcomings of present state of the art systems while presenting a reliable, compact, and cost efficient system of producing hydrogen-oxygen gas without requirements or investments into expensive infrastructure or cumbersome equipment.

4. BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view showing one embodiment of the compact hydrogen generator according to the present invention.

FIG. 2 is a front view showing another embodiment of the compact hydrogen generator according to the present invention.

FIG. 3 is a side view showing another embodiment of the compact hydrogen generator according to the present invention.

FIG. 4 is a top view showing another embodiment of the compact hydrogen generator according to the present invention.

FIG. 5 is an alternative front view showing another embodiment of the compact hydrogen generator according to the present invention.

FIG. 5 a is a close up view of section 5-5 in FIG. 5 showing an alternative electrode embodiment according to the present invention.

FIG. 5 b is an alternative front view of FIG. 5 showing another embodiment of section 5-5 in FIG. 5 of compact hydrogen generator according to the present invention.

FIG. 6 is a top view of an alternative embodiment in FIG. 5 of the compact hydrogen generator according to the present invention.

FIG. 7 is a front view of FIG. 2 showing one embodiment of the compact hydrogen generator without fittings or bolts and fasteners in place

FIG. 8 is a cross section view in detail of the portion indicated by the section lines 7-7 in FIG. 7

FIG. 9 is a sectional view of one inner cell of the compact hydrogen generator according to the present invention, with front plate and electrode removed for clarity.

FIG. 10 is a sectional view of one inner cell of the compact hydrogen with End Plate, electrode, and one inner plate removed for clarity, showing the water/electrolyte solution and the generated gas as it is produced in the compact generator according to the present invention.

FIG. 11 is a front view of one electrode of the compact hydrogen generator according to the present invention

FIG. 12 is a view of FIG. 10 with electrode of FIG. 11 in position, shown in a semi-transparent mode to reveal its relation to the remaining parts of the compact hydrogen generator according to the present invention.

FIG. 12 a is an alternative embodiment of the compact hybrid cell hydrogen generator showing one possible multi-faceted iteration.

FIG. 12 b is an alternative embodiment of the compact hybrid cell hydrogen generator showing one possible cylindrical iteration.

FIG. 13 is a front view of FIG. 2 showing one embodiment of the compact hydrogen generator with bolts and fasteners, but without fittings in place.

FIG. 14 is a close-up cross section view in detail of the portion indicated by the section lines 13-13 in FIG. 13 showing bolt and fastener detail.

FIG. 15 is a cross section view of another embodiment of the portion indicated by the section lines 13-13 in FIG. 13 showing an alternative fastener detail.

FIG. 16 is an exploded perspective view showing another embodiment of the compact hydrogen generator according to the present invention.

FIG. 17 is a side view of another embodiment of the hybrid cell hydrogen generator utilizing a manifold for exiting gases.

FIG. 18 is a side view embodiment of the hybrid cell hydrogen generator showing manifolds for both ingoing water/electrolyte mixture and the outgoing hydrogen-oxygen gas.

FIG. 19 is one embodiment of an electrical schematic with an alternative method for powering alternative embodiments of the compact hydrogen generator.

FIG. 20 is one embodiment of a plumbing schematic for fluid and hose connections.

FIG. 21 is a chart of an emissions test performed on a test vehicle with our compact hybrid cell hydrogen generator system installed.

FIG. 22 is a bar graph of the reduction in Hydrocarbons indicated in chart of FIG. 21

FIG. 23 is a bar graph of the reduction in Oxides of Nitrogen as indicated in chart of FIG. 21 FIG. 24 is a bar graph of the reduction in deadly Carbon Monoxide as indicated in chart of FIG.

LIST OF REFERENCE NUMERALS

-   30. end plate -   31. end plate alternative -   32. bolt -   33. electrode -   34. alternative electrode -   35. alt electrode -   36. electrode gasket -   37. nut -   38. inner cell casing -   39. upper elbow fitting -   40. lower elbow fitting -   41. upper straight fitting -   42. lower straight fitting -   43. inner gasket -   44. inner plate -   45. through hole for bolt assembly -   46. threaded hole for fittings -   47. fluid return channel -   48. gas accumulation chamber -   49. water/electrolyte mixture -   50. hydrogen-oxygen gas -   51. electrode gas exit channel -   52. water/electrolyte mixture entrance channel -   53. electrolytic process chamber -   54. washer -   55. bolt insulator tube -   56. rivet -   57. inner cell sub assembly -   58. manifold inlet tube -   59. gas manifold -   60. battery array -   61. inverter -   62. diode bridge array -   63. capacitor -   64. hydrogen generator -   65. hose -   66. reservoir -   67. bubbler/filter -   68. dryer/safety flashback arrestor -   69. air intake of the internal combustion engine -   70. gas manifold sub assembly -   71. alternative inner gasket

DETAILED DESCRIPTION OF THE INVENTION

In one embodiment of the compact Hydrogen Generator, the fully assembled unit with bolts, fittings and exposed electrode connection points which can be seen in FIG. 1. As seen In FIG. 2, FIG. 3, and FIG. 4, and FIG. 8, a generator is comprised of an inner cell casing 38, which contains a number of metal inner plates 44 separated by inner gaskets 43, and is sandwiched between electrodes 33, gaskets 36 and end plates 30. Gaskets 36 sandwich the electrodes 33 to prevent leaks, and are compressed to a predetermined specification by bolts 32, washers 54 and nuts 37.

Elbow fittings 39 and 40 are inserted into threaded holes 46 on end plates 30 in this embodiment. Typically in this configuration, the water/electrolyte mixture 49 enters the generator in a liquid state through lower elbow fitting 40, and exits in a saturated gaseous state through upper elbow fitting 39. The DC (direct current) electricity is introduced by connection to the electrodes 33 through various means of attachment common to the trade, at least one electrode 33 becoming the anode, and at least on electrode 33 becoming the cathode.

The inner cell sub assembly 57 in FIG. 8, which is a cross section of 7-7 in FIG. 7, shows an assembled embodiment of the compact hydrogen generator including end plates 30 inner cell casing 38, gaskets 36, electrodes 33, inner plates 44 and inner gaskets 43, as well as electrolytic process chamber 53.

The bolts 32 shown in FIG. 14 are inserted in a through hole for bolt assembly 45 and in this embodiment are insulated from electrodes 33 with a bolt insulator tube 55 to prevent electrical shorting, and the combined bolts 32, washers 54, nuts 37, and bolt insulator tube 55 serve to compress and hold the inner cell sub assembly 57, gaskets 36, and end plates 30 together in one method of this embodiment.

In another embodiment multiple inner cell subassemblies 57 can be stacked together to form a larger compact hydrogen generator for more hydrogen-oxygen gas 50 production as shown in FIG. 17 and FIG. 18, and the hydrogen generator is not limited to just one inner cell subassembly 57, though it can function quite well with just one inner cell subassembly 23, with electrodes 33, gaskets 36, and end plates 30 as shown in FIG. 1.

When many inner cell subassemblies 57 are joined together as in FIG. 17, there are several particular and unique advantages recognized that are specific to this embodiment. As shown in FIG. 17 the same inner cell casings 38, gaskets 36, and end plates 30, are used as outlined and detailed in these specifications.

However, in a cross hybrid embodiment between the generator assembly in FIG. 2 and the generator assembly in FIG. 5, the lower straight fittings 42 are assembled in end plates 30 but the upper straight fittings 41 are connected with a gas manifold 59 which is interconnected with a series of manifold inlet tubes 58. This is hugely advantageous over prior art as it allows an efficient laminar convection flow of water/electrolyte mixture 49 and the resultant larger volume of hydrogen-oxygen gas 50 in a smooth laminar flow and improved fluid dynamics.

FIG. 18 shows an alternative embodiment to FIG. 17 with manifold inlet tubes 58 interconnected with gas manifold 59 together comprising a gas manifold sub assembly 70. In this embodiment a gas manifold sub assembly 70 is used in lieu of the upper straight fittings 41 and the lower straight fittings 42 as shown in FIG. 5. The said fittings 41 and fittings 42 are shown in this embodiment of FIG. 18 are now connected to the gas manifold sub assembly 70.

Alternatively, the embodiment in FIG. 17 and FIG. 18 can have many additional inner cell subassemblies 57 and be configured in a particular way as to run on much higher DC (direct current) voltages of 120 volts, 240 volts, or even 480 volts or higher, using a rectified voltage as shown in the electrical schematic in FIG. 19, with no degradation or reduction of laminar flow.

In one embodiment the 12 volt or 24 volt battery 60 is connected to inverter 61 which changes the DC (direct current) into AC (alternating current) and increases said voltage to 120 volts AC as shown in FIG. 19. The output 120 volt AC signal is then rectified through a full wave diode bridge array 62 as shown in FIG. 19 and as is common to those skilled in the trade. The 120 volt rectified DC (direct current) is then fed into the anode and cathode electrodes 33 of the hydrogen generator 30, allowing a more efficient energy input of higher voltage but lower amperage, lessening the power drain on the vehicle or engine alternator.

In another embodiment, inner cell subassemblies 57, end plates 30, gaskets 36, electrodes 33, metal inner plates 44 separated by inner gaskets 43, can be configured as a round assembly as shown in FIG. 12 b and are not constrained to only the square configuration embodiment detailed in these specifications.

In another embodiment, inner cell subassemblies 57, end plates 30, gaskets 36, electrodes 33, metal inner plates 44 separated by inner gaskets 43, can be configured as a multi-faceted assembly such as shown in FIG. 12 a, but not limited to: hexagon, octagon, pentagon, or other various multi-faceted designs, and are not constrained to only the square configuration embodiments detailed in these specifications.

In another embodiment, inner gaskets 43 can be joined together in a tray like arrangement (not shown) as clips that can fasten to the inner plates 44 to act as both spacers, plate holders, and edge protectors to expedite assembly of larger hydrogen generators with large numbers of inner plates 44.

In another embodiment, inner gaskets 43 can be substituted with one embodiment but not limited to alternative inner gasket 71 as shown in FIG. 9.

Alternatively, an even slimmer embodiment of the compact hydrogen generator in FIG. 5 uses the same configuration of an inner cell casing 38, which contains a number of metal inner plates 44 separated by inner gaskets 43, and is sandwiched between electrodes 33, gaskets 36 and end plates 30. Gaskets 36 sandwich the electrodes 33 to prevent leaks, and are compressed to a predetermined specification by bolts 32, washers 54 and nuts 37. But instead of the Elbow fittings 39 and 40 inserted into threaded holes 46 on end plates 30, this embodiment uses end plate alternative 31 which has no threaded holes 46 on end plate 30. The water/electrolyte mixture 49 enters the compact hydrogen generator through fitting 42 and exits as hydrogen-oxygen gas 50 through fitting 41. This presents an even slimmer embodiment and is the preferred method for an ultra slim compact hydrogen generator.

In another embodiment, the exposed tab of electrode 33 can be processed with a hole as in alternative electrode 34 of FIG. 5 a for easier electrical hookup as is common to anyone skilled in the trade.

In another embodiment shown in FIG. 5 b, the end plates 30, inner cell casing 38, and gaskets 36 can be made in such a manner as alternative end plate 31 as to expose a section of alternative electrode 35 without an extended tab as shown in FIG. 5.

In another embodiment gas accumulation chamber 48 in FIG. 9 can be changed in size, shape, and angle and is not limited to that shown in FIG. 9.

In another embodiment fluid return channel 47 in FIG. 9 can be changed in size, shape, and angles and is not limited to that shown in FIG. 9.

In another embodiment water/electrolyte mixture entrance channel 52 can be changed in size, shape, and angles and is not limited to that shown in FIG. 11.

In another embodiment electrode gas exit channel 51 can be changed in size, shape, and angles and is not limited to that shown in FIG. 11.

In another embodiment the inner gaskets 43 can be changed in size, shape, and angles and is not limited to that shown in FIG. 9, FIG. 10, or FIG. 12

In another embodiment gaskets 36 in FIG. 16 can be changed in size, shape, and angles and is not limited to that shown in FIG. 16. Alternatively, gaskets 36 can be substituted with specially shaped o-ring gaskets (not shown).

In another embodiment the plumbing schematic can be modified from that shown in FIG. 20

Operation of Invention

As water/electrolyte mixture 49 is introduced into the compact hybrid cell hydrogen generator through lower elbow fittings 40 or 42, it enters through the water/electrolyte mixture entrance channel 52 in electrode 33 and passes through the fluid return channel 47, filling up the electrolytic process chamber 53. As voltage and current are applied to extended contacts of electrodes 33, electrolysis occurs in the electrolytic process chambers 53 and hydrogen-oxygen gas 50 is disassociated from water/electrolyte mixture 49, rising up the electrolytic process chambers 53 where it gathers in a specially configured gas accumulation chamber 48. From there, the hydrogen-oxygen gas 50 pressurizes and goes through electrode gas exit channel 51, and out upper elbow fittings 39 or 41 in the form of a saturated hydrogen-oxygen gas, which is a mixture of both the water/electrolyte mixture 49 and the newly disassociated hydrogen-oxygen gas 50.

The saturated hydrogen-oxygen gas then exits the hydrogen generator 64 through the hose 65 and into the reservoir 66 as seen in plumbing schematic FIG. 20. The heavy water/electrolyte mixture 49 drops via gravity back into the water/electrolyte mixture 49 in the reservoir, where it continues the gravity fed convection circulation back into the bottom fittings 40 or 42 of hydrogen generator 30 to start the cycle again. The reservoir is generally filled ⅔ with water/electrolyte mixture 49, and the remaining ⅓ space at the top of the reservoir contains the lighter hydrogen-oxygen gas 50 which has separated out from the water/electrolyte mixture 49, being lighter in its gaseous form. The hydrogen-oxygen gas 50 then circulates into a secondary bubbler/filter 67, then alternately through a dryer/safety flashback arrestor 68. From there it is drawn into the air intake of the internal combustion engine 69, where it mixes with existing air/fuel ratio of internal combustion engine and ignites along with it during the combustion process, enhancing the burn and lowering emissions by injection of the clean hydrogen gas (which burns ten times faster than gasoline), in conjunction with approximately 34% pure oxygen.

The form of hydrogen-oxygen gas 50 as produced in my present invention is both volatile and energetic, and should not be pressurized above a certain threshold. This form of on-demand hydrogen generation has been shown in many instances to greatly enhance the combustion process, extract more energy out of the fuel, and significantly reduce emissions as shown in the included chart of FIG. 21, and the bar graphs in FIG. 22, FIG. 23, and FIG. 24.

While I believe the reaction occurs because of the catalytic effect of introducing a small amount of hydrogen-oxygen into the combustion process, I don't wish to be bound by this.

The introduction of this specialized hydrogen-oxygen gas does appear to extract more energy out of a given volume of combustible hydrocarbons, resulting in the lowering of noxious fumes and emissions, and resulting in a much more thorough extraction of energy from fuel that would normally be wasted as heat and exhaust. Many of our customers have reported a very sweet smelling exhaust, and I myself can attest to a slight ozone smell, though this is purely anecdotal and not substantiated in present supporting documents included in this application.

There is not enough volume produced in this style of on demand compact hydrogen generator to replace hydrocarbonic fuels, but it works perfectly in conjunction with the fuel to create a faster burn, extracting more energy out, before the gases exit the internal combustion engine. It is also of very slim design and compact as a hydrogen generator, making it easier, cheaper, and quicker to install.

CONCLUSION, RAMIFICATIONS, AND SCOPE OF THE INVENTION

Thus the reader will see that the compact hybrid cell hydrogen generator of the invention provides a highly reliable, very compact and efficient device that can be fit into almost any vehicle, mobile unit, or static fuel based generators. It can be used to drastically reduce contaminants from fuel and extract more energy out of the combustion process, positively impacting our environment and eco-system.

While my above invention contains many specificities, these should not be construed as limitations on the scope of the invention, but rather as an exemplification of one preferred embodiment thereof. Many other variations are possible. For example changing the overall shape to cylindrical or hexagonal instead of the square one indicated in this embodiment. Or the use of more exotic metals instead of stainless steel such as platinum, cobalt, nickel, titanium or other various coated metals with possibly applied catalysts. Other variations include using different fastening systems than the bolts/nuts or rivet embodiments shown. Other variations include revisions in the thickness and solidity of the inner cell casing 38 structure and design which would be better suited to an o-ring application. Other variations including size of overall hydrogen generator and/or mounting brackets or holes. Other variations include integrating water coolant channels in the inner cell casing 38 for keeping steady temperatures. Still other variations include use of specially designed pressure relief valves, vacuum relief valves, and specially vented solenoid check valves. Another example is integration of vibratory equipment. Yet another example is integration of higher voltage pulsed through a capacitor bank into a resonant circuit. Yet another example is integrating highly energetic magnetic coils.

Accordingly, the scope of the invention should be determined not by the embodiments illustrated, but by the appended claims and their legal equivalents. 

1. Apparatus for decomposing water and electrolyte solution into hydrogen and oxygen gases in an electrolytic process chamber for use with an internal combustion engine, the system comprising: a housing adapted to contain said solution, said housing substantially sealed and wherein gases produced exit the housing via inlet and outlet apertures; said electrolyte solution partially filling said electrolysis chamber and gathering in a gas accumulation chamber there above in said chamber; a water supply means adapted to maintain said electrolyte; a plurality of regularly spaced metallic plates; a fluid flow passageway wherein each of said apertures are within the periphery of the housing being positioned such that at least some of the fluid entering the fluid flow passageway through the inlet and exiting through the outlet flows through at least one section of the fluid flow passageway; at least one anode and one cathode with an entrance channel and an exit channel therein, positioned such that application of an electrical potential across such electrodes causes field lines to pass through the at least one section of said electrolytic process chamber comprised of at least one said metallic plate. a collection means for gases produced by said electrolysis. A collection means comprising a method for purifying and filtering said gases A means to introduce said gases into air intake of internal combustion engine A collection means comprising a method for preventing flashback of said gases.
 2. The apparatus of claim 1 wherein said housing is slim and compact, held together and clamped by bolts, washers, nuts, or rivets, or any other means that can effectively hold apparatus together in a manner to prevent leaks of the solution and the gases.
 3. The apparatus of claim 1 wherein said housing is comprised of acetal homopolymer resin, acetal copolymer or other means of high temperature resistant plastic.
 4. The apparatus of claim 1 wherein said fluid flow passageway comprising a fluid return channel beneath said plates, between said anodes and said cathodes through the entrance and exit channels, interconnecting with said electrolytic process chamber and interconnecting the chamber with said gas accumulation chamber above said metallic plates, whereby said solution and said gases pass through the entrance and exit channels therein.
 5. The apparatus of claim 1 wherein the said metallic plates, said anodes, and said cathodes may be comprised of stainless steel, titanium, nickel, platinum, cobalt coated metals, or other metallic means, and said metallic plates may be combined with one or any combination of said metallic means.
 6. The apparatus of claim 1 wherein said metallic plates are held in place, evenly spaced, and mechanically insulated from each other and the exposed edges of said metallic plates therein by a specially designed inner gasket or means, said gasket or means covering partial face of and around said edges of said plates, whereby sealing them from possible current losses in the electrolytic process.
 7. The apparatus of claim 1 wherein the inner cell casing of said housing, containing the metallic plates and said gaskets or means, can be interconnected with multiple inner cell casings containing the metallic plates and said gaskets or means, through fastening means to ensure said housing substantially sealed and wherein gases produced exit the housing via the inlet and the outlet apertures.
 8. The apparatus of claim 1 wherein said inlet and outlet apertures can be arranged on said periphery or on the top and bottom of inner cell casing, or any means therein of said periphery and said cell casing; said apertures penetrating therein said gas accumulation chamber and said fluid return channel interconnected to said electrolysis chamber, said plates and said inner gaskets.
 9. The apparatus of claim 1 wherein said inlet and outlet apertures can be interconnected through an external manifold or means in a method to combine said hydrogen and oxygen gases, or to combine said water and electrolyte solution, or any combination therein.
 10. The apparatus of claim 1 wherein said anode and said cathode, and said metallic plates can be arranged through means to operate from 12-480 volts direct current or higher with said means. 